Integration and visualization of rapid prototyping and reverse engineering

Rapid prototyping, where a part is built gradually by adding materials layer-by-layer, is fully automatic and it offers many advantages over traditional manufacturing processes. Integrating reverse engineering and rapid prototyping technologies can facilitate the process of product development. Data transfer is critical in integrating reverse engineering and rapid prototyping process cycle. It must be efficient and free from errors or ambiguity. The processing of data clouds, from the laser scanner, was investigated in this thesis. Three integration approaches ((i) 3-D model direct slicing. (ii) Mesh generation from unstructured data cloud (Sun, 2001). (iii) Slice contour file generation directly from data cloud (Lee, 2001).) have been implemented. The advantages and disadvantages of approaches are examined through case studies.; A visual simulation system has been developed for simulating rapid prototyping process—FDM (Fused Deposition Modeling). The visual simulation technique simulates the part prior to fabricating the physical model. Careful examination of the virtual prototype before the actual fabrication can help minimize unwanted design iterations. The visualization capability of the system is demonstrated by comparing virtual prototypes with corresponding physical prototypes. (Abstract shortened by UMI.)...